Operations Manager Maintenance
Resume:
Jerry W Moore
Surgoinsville, TN 37873
Cell 423-***-****
********@*****.***
Core competencies include:
Strategic Business Planning Environmental,Health & Safety Coaching & Mentoring
Lean / TPS Continuous Improvement Team Leadership
Maintenance / Operations Management Director of Maintenance 2019 – 2025
Bharat Forge PMT
Surgoinsville, TN
Operations Manager, Project Engineer, Maintenance Manager Environmental Manager & Safety Director
Bharat Forge is the World’s Leader in forging pistons. We service customers such as Cummins, John Deere, Caterpillar, General Motors, Chrysler, Volvo just to name a few. Company Projects:
• Implemented SAP system in the Maintenance Dept.
o MRO Inventory Control
o Work Order System
• Implemented maintenance methodologies and processes. o Impact to the business
PM & CBM vs Breakdown & Systemic issues
• We took maintenance downtime from 19% to 8.7 % in 2021 & 2022
• Understanding the difference between Symptom vs Root Cause
Improved our PM program
Problem Solving
Troubleshooting
• Integrated Maintenance Dept with Operations to execute TPM efforts across the depts. Responsibilities:
• Maintenance Manager – 4 shifts, 21 employees. 2 engineers. Developing and obtaining KPI’s set forth.
• Participate in strategy and profit planning. Also includes capital expenditures.
• Work and coordinated activities with outside contractors
• Maintain and improve (always ongoing) infrastructure and equipment PM.
• Understanding of Gaps in the Maintenance Shop, assisting in identifying Gaps in waste, throughput targets and all areas that impact the business.
• Environmental Manager – Responsible for ISO-14001 Audits, regulatory items (Air Permitting), etc..
• Safety Director – Responsible for monthly Leadership Training, ensure forklift, lockout tagout and training and many more mandates from OSHA are executed. Develop annual training plan.
• Operations Manager – Responsible for cycle rates, labor allocation, developing and obtaining KPI’s, daily planning, working with all Depts to ensure we all are successful.
• Project Engineer – Responsible for Capital, equipment reliability and 8 million Capital budget. 2016 – 2019
Shearer's Foods, LLC
Bristol, VA
Technical Manager
Shearers in the largest private brand snack manufacturer in the United States. We service customers such as Wal Mart, Kroger, Food Lion, just to name a few. We ship all over the world. In the Bristol facility we produce potato chip and tortilla products.
Company Projects:
• Most of our equipment is chain and sprocket driven. o Our corn wash tumbler assembly has this power transmission. Over a 9 month period of time this assembly has caused 130 hrs of downtime, even before my arrival. Designed a new shaft, added 2 new Allen Bradley 525 drives and Sew Euro gear motors. This effort with the Maintenance Team resulted in 2.5 hrs of dt over the next 9 months. Including labor loss, waste and production, this equated to a $11k cost savings.
This type of “Designing out the Issue” was executed in 3 more areas of the plant. With a total cost savings of $96k.
• Redesigned, installed new Environmental System to meet / exceed regulatory compliances. Working with BVU / Inframark and other city and state officials. We have taken the plant to a new level. November 2018 was the first time in 11 years with “No Excursions” or “NOV’s”. Responsibilities:
• Technical Manager for the Maintenance / Engineering Dept, PM Crew, MRO Inventory & Environmental
• Managing a 2.2 million dollar budget.
• Participate in strategy and profit planning. Also includes capital expenditures.
• Maintain records for certain OSHA requirements i.e. crane & hoist inspections.
• Maintain records for SGF / AIB Food Safety Audits.
• Work and coordinated activities with outside contractors.
• Developed tooling PM process.
• Maintain and improve (always ongoing) infrastructure and equipment PM.
• Understanding of Gaps in the Maintenance Shop, assisting in identifying Gaps in waste, throughput targets and all areas that impact the business.
2007 - 2016
Exide Technologies
Bristol, TN
Maintenance / Engineering Manager
Exide manufacturers lead acid batteries for OE customers such as Toyota, BMW, Nissan, John Deere, NASCAR and some aftermarket customers. The facility is approx. 850,000 square feet. Company projects:
• Installed, setup and integrated the CMMS (MP2 Data stream) for PM’s, Work Orders, MRO inventory control.
• Redesigned vacuum system for assembly. Have 11 lines, were using 2 per line. 2 month project to reduce to 1 per line. An annual energy cost savings of $45,000.
• Six Sigma Project - Redesigned pasting tooling to extend life (went from 9 million plates to 21 million plates) and reduce scrap. Total project was 3 months and an annual savings of 1.2 million dollars.
• Facilitated various Kaizen teams for reducing scrap, increasing throughput, reducing downtime, increasing efficiencies, identifying waste and improving processes.
• Selected as a member of the Executive BAMA (Bluegrass Automotive Manufacture Association) An Executive event with a project for a specific area of concern. The goal was to decrease cost 45% and increase throughput by 25%. Goals were achieved.
• Support all EHS initiatives.
o Hazardous Waste Streams, Safety Gemba Walks, Train Lockout / Tagout Responsibilities:
• Dept manager for the Maintenance Dept, Machine Shop, Fab Shop, Tooling. Setup, MRO Inventory and PM crew. 68 hourly and 7 salary employees.
• Managing a 4 million dollar budget.
• Participate in strategy and profit planning. Also includes capital expenditures.
• Maintain records for certain OSHA requirements i.e. crane & hoist inspections.
• Maintain records for TS/ISO Audits.
• Worked and coordinated activities with outside contractors.
• Developed tooling PM process.
• Maintain and improve (always ongoing) infrastructure and equipment PM.
• Facilitator for the safety program.
• Training for such programs as Lockout/Tagout, hydraulic troubleshooting, blueprint reading, identifying abnormalities, TPM and assist in deployment of the Toyota Production System. 2005 - 2007
Hutchinson Sealing Systems
Church Hill, TN
Maintenance Manager
Hutchinson Sealing Systems is a leader in door / window sealings for the automotive industry. Primary customers are Chrysler, Ford and General Motors.
Company projects:
• Participated in the installation of a new extrusion line.
• Installation of various presses in our Church Hill and Wytheville plant.
• Champion for reducing scrap and downtime on our end of the line saws. Removed mechanical operation and installed electronic detection. Reduced downtime by 60% and scrap by 45%.
• Setup advanced techniques for PM’s to our molding presses. These job tasks actually became instrumental in our troubleshooting process of the press: hydraulic calibrations, temperature controller verification, press parallel, utilizing a strain gage for tie rods.
• Management process audit team, safety.
Responsibilities:
• Management of Electrical and Mechanical Engineers, Maintenance Department, Machine Shop.
• Responsible for equipment, implementing PM’s, troubleshooting techniques at our Wytheville, VA plant.
• Worked and coordinated activities with outside contractors. 1992 - 2005
Eaton Corporation / Golf Pride Grips
Laurinburg, NC
Plant / Maintenance Manager
Eaton Corporation / Golf Pride Grips is a rubber company that manufacturers golf grips for some of the biggest names in the market including Taylor Made, Ping, Titleist, Calloway and many others. Worked in various other plastic and rubber plants within Eaton Corporation. Company Projects:
• Served as Project Manager responsible for the rebuilding of our Farrell Mixer and hopper assembly. This involved installing a 400hp Reliance AC frequency drive, a new PLC, a touch screen Panelmate and data acquisition.
• Responsible for the purchase of the new Computerized Maintenance Management System
(CMMS), DP Solutions. This system is on line and tied into our network on the AS400 where we use it for preventive maintenance, breakdowns, projects, inventory control functions and equipment analysis. This is integrated into our company network.
• Tasked with the facility energy management, calculated lighting controls and loads, installed new non-moving steam traps and a chilled water system. Also responsible for working with the gas company on gas prices on the NYMEX, introducing RTP (Real Time Pricing) with the power company (CP&L), installing high efficiency motors, and various other energy cost reduction programs which resulted in a 2006 ytd savings of $216,000.
• Assisted in the design and the purchase of an ultrasonic cleaner that moves our molds from station to station via a robot. This saves on wear and tear of our intricate artwork of cavities. It too uses a touch screen Panelmate and Siemens controller.
• Assisted in the design and the purchase of a waterjet cutter. This machine cuts our cord material to whatever we want. This is PC controlled using linear Kollmorgen Drives. And, was responsible for creating the CAD drawings for the offload automation. This resulted in $125,000 a year in cost savings; labor and scrap.
• Project Manager and designer in many of our press rebuilds. Responsibilities included creating the CAD drawings, ordering parts, programming and debugging, and using operator interfaces for process control on hydraulic systems.
• Served as project manager on purchasing a new CNC lathe and mill for our machine shop.
• With our Company converting over to a new process, MFG Pro, we also had to upgrade our CMMS System. Project manager over the new CMMS System MP2 from Data Stream.
• Dept Manager for 38 maintenance personnel and 3 salary. Responsibilities:
• Management of Engineering, Maintenance Department, Mold Setup Department and Machine Shop.
• Decrease maintenance downtime and reduce tooling setup time.
• Assisted in the CNC training for men in the shop at a local college.
• Worked and coordinated activities with outside contractors.
• Green Belt projects under the Six Sigma guidelines.
• ISO 14001 internal auditor.
• Implementation of Total Productive Maintenance, also OEE Division wide. Using the 8D and Six Sigma methods. Introducing “autonomous maintenance”.
• Champion over several Kaiezan events.
• Strategic planning and profit planning. Accountable for well over $5 million in budgets involving replacement tooling, maintenance expenses, labor, utilities and training.
• Continuous improvement activities involving process improvements, automation and integration, increasing productivity, cost savings, reduction of scrap, maintenance of the CMMS and the training of maintenance personnel.
• Implementing and deploying the lean Concepts.
• Champion for both employee and staff safety committee meetings.
• Project manager over new CMMS for maintenance / machine shop and tooling database. Installed and networked DataStream MP2 system.
1983-1992
Rockwell International/Automotive
Newton, NC
Maintenance Supervisor / Maintenance Manager
Rockwell International/Automotive is a plastics company producing primarily rocker arm covers for Ford Motor Company. They also make fan shrouds, engine sound shields for Ford vans, and windshield surround frames for the Dodge Viper. We mixed our own raw materials, (vinyl ester resin and & glass) with a planetary type mixer, extruded the material and let it set in a maturation room for a specified amount of time. We had several presses ranging from 150 tons to 1300 tons. They do business with Ford, Chrysler, Honda and GM. This was a 24/7 operation. Company Projects:
• Designed and built hydraulic power units for auxiliary circuits to be used in the coring and ejection functions of molding presses.
• Converted seven presses from relay logic controlled to PLC controlled using the A&B slc 500 family of controls. Responsibilities included the design of control panels, creation of CAD drawings, ordering of parts, programming and debugging, and finally the installation of machine on the line.
• Assisted in the design of a robot using fiber optics to detect the bolt and stud pattern on rocker arm covers. This involved the use of an A&B PLC control integrated with a videojet printer that printed the date, time and shift on each cover.
Responsibilities:
• Implementation and maintenance of ISO/QS procedures focusing on improvement.
• ISO 9000 internal auditing.
• Evaluation and advising of new and existing equipment.
• Automating of equipment where possible to improve the process. This involved working hand in hand with manufacturing.
• Worked and coordinated activities with outside contractors.
• Training of the following personnel:
- Maintenance – hydraulic systems, blue print reading, PLC programming, troubleshooting ladder logic on a laptop, installation and setup of electronic equipment including proportional cards, power supplies, pressure transducers, etc.
- Manufacturing Supervisors/Group Leaders – training consisted of their responsibilities for specific pieces of equipment including safety issues, process parameters and their effects on the machine, actual machine controls, etc.
(Note: These training sessions were filmed and used for training aids and for advancement requirements.)
• Purchase, installation, set up and training of personnel on the CMMS. Responsible for setup and implementation of the preventive maintenance program. Also integrated breakdown work orders and inventory control functions into the system.
Education:
Noblesville High School
Noblesville, IN
1979
US Navy
USS Dwight D Eisenhower CVN 69
Nuclear Aircraft Carrier
Petty Officer 3
rd
Class
Norfolk, VA
1979-1983
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Intro to PLC Hickory, NC
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Zenger Miller – Frontline Leadership Training (2wk course) Cleveland, OH Conflict Management Training (I & II) Cleveland, OH Eaton Management Excellence Training (EME) Cleveland, OH Positive Management Training Cleveland, OH
Sandhills High Performance Management (Team Building) Pinehurst, NC ISO 9000 Documentation Hickory, NC
ISO 14001 Internal Auditor Training Laurinburg, NC AMMS – Advanced Maintenance Manager System (CMMS) San Diego, CA Bearing Maintenance – Care & Troubleshooting Hickory, NC Swagelok Seminar – Sizing of tubing, fittings & applications Charlotte, NC Aeroquip Seminar – Proper hose & crimping procedures Hickory, NC Loctite Seminar – Proper uses & applications Hickory, NC Project Management – Marshall Institute Atlanta, GA World Class Maintenance – Marshall Institute Myrtle Beach, SC Six Sigma Green Belt Cleveland, OH
Lean Manufacturing Laurinburg, NC
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BAMA Executive Overview Bristol, TN
DOT / RCRA Certified Bristol, TN
I Microsoft Office, Microsoft Project, Microsoft PowerPoint for formal/informal presentations, SAP, MP2 Datastream and many other software programs.
I am a hands-on type manager.
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